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State of the Plant Meeting Review Of January – February 21, 2012. Introduction – Mark Shelley Safety –Ed Chojnicki Plant Financial Performance – Simon Michael Manufacturing – Fred Espinoza / Raul Reyes Plant OTD Performance – Stephen Law Quality – Mark Shelley
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State of the Plant Meeting Review Of January – February 21, 2012
Introduction – Mark Shelley • Safety –Ed Chojnicki • Plant Financial Performance – Simon Michael • Manufacturing – Fred Espinoza / Raul Reyes • Plant OTD Performance – Stephen Law • Quality – Mark Shelley • Kaiser LA Vision/Direction (Update) – Mark Shelley • Kaiser®Select– Tom Gannon – VP of Sales/Marketing
PLANT FOCUS • Operational Efficiency • Maximize Metal Profits • Mix Rationalization • KaiserSelect® • EHS Culture/Sustain
Key Points: • Cast house , 4000 TP & 2400 TP manufacturing efficiencies are key drivers for the positive EBITDA • Good spending control – R&M spending, OT, and Deval October Financial Results January- 2012 Financial Results $265K (EBITDA) = Total Revenues Total Costs = Break Even Revenues Costs Improved Customer Service Increases Revenues Improved Efficiency Lowers Cost
Controllable Mfg. Cost – Earned vs. ActualAnd Press Efficiency Trends 6
2011 Kaiser Values – Valued Corporate Citizen LCIR 2012 Key Plant Focus Initiative 7 7
2011 Key Initiatives – October Status • EHS Performance • No recordable injuries in January • Hard hat policy in December • Implementation of adding disposable plastic bottles to the banned from the plant list. • 2012 key focus on using the FMEA for focus to the safety initiatives. • Continued emphasis on separation of pedestrians from mobile equipment.
ON TIME DELIVERY DETAIL 2011 Feb-March: Schedule issues LA/KMZ, system. Mill driven. DT balance of majority of monthly issues 11
External Quality Justified Claim Free Performance % Of Line Items Justified Claims Average Average #claims per month
Lean Sigma (CI) • Key Initiatives (SDx) • Safety • BIC Customer Service • Quality Performance • Controllable Cost • Capacity/Other • Summary
2011 Key Initiatives – Press Efficiency Overall Press Efficiency Recovery Impact= -11% Efficiency ’08 vs. ‘09 New equipment was installed at the end of 2008.
4000 Press Efficiency 4000 TP Efficiency 17
2400 Press Efficiency 2400 Press Efficiency 19
1650 Press Efficiency 1650 Press Efficiency 21
2012 Cast House Pounds/Cast Hour Operating Melter Furnace 1 1 2 2 2 2 1 1 1 1 1 2 1 1 1 1 1 1 23
Cast House Efficiency Cast pounds/labor hr August 2011 3,032 lbs/lbr.hr in 21 casting days January 2012 3,296 lbs/lbr.hr in 19 casting days
Cast House Efficiency Metal Profit
2012 PLANT FOCUS • Resolution of NOx Compliance • Meeting Cast House burner NOx compliance • ISO14001 Compliance • EHS Risk Reduction • Ergonomics • Press Downtime Reduction • Controllable Manufacturing Variance • Enhancement of Engineering/Maintenance • Systems, Practices, Capabilities, Management, Spending • Achieving 98% Service Levels for “A” and “B” Items • Maintain Competitive Lead Times
Mix Rationalization Strategy • Established a “Mix Rationalization Strategy” for the Plant • Mix Rationalization Team – Marketing, Sales, and Manufacturing • Established Team Strategy • Implementation of Strategy underway • Heat Sink exit strategy underway • Excessive lengths exit strategy underway • Fabrication strategy implementation • “Specific” financial, processing, “noise” analysis & exit strategy • Example: KenFabrica • Leaded Alloy Exit Plan – February 2012 28
2011 KaiserSelect® Product Introductions • KaiserSelect® Rod Implementation – Q1 - 2011 • Rod Diameter: 0.75” - 3.00” (COMPLETE) • KaiserSelect® Manifold Bar – Q2 • 2.00” – 8.00” (COMPLETE - ONGOING) • KaiserSelect® Large Rod – Q3 • Rod Diameter: 3.00” – 8.5” (COMPLETE – Q1 – 2012) • KaiserSelect® Log/Billet – Q4
